OAQ Process Information Application PI-15 Portland Cement Manufacturing {52556}

Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 1 of 5 PI-15 Instructions 10/2006 PROCESS INFORMATION: Portland Cement Manufacturing ­ INSTRUCTIONS Microsoft Word version of PI-15 Adobe PDF version of PI-15 The purpose of PI-15 (state form 52556) is to obtain detailed information about the Portland cement manufacturing process. Complete one form for each process (or group of identical processes). PI-15 is a required form for all air permit applications submitted to IDEM, OAQ. For the purposes of this form, the term "source" refers to the plant as a whole and NOT to the individual emissions units. If you do not provide the enough information to adequately describe the process, the application process may be stopped. If you have any questions, contact the Air Permit Reviewer of the Day (PROD) at (317) 233-0178 or 1-800-451-6027 extension 3-0178 (toll free call within Indiana). Part A: Elements of Portland Cement Manufacturing Part A identifies the processes related to Portland cement manufacturing and additional forms that may be needed. For each process listed, specify the form(s) attached. If a listed process is not applicable to the process, choose "N/A". If there is another process applicable beyond the listed items, specify the process under the "other" option, and identify any additional forms used to describe the process. 1. Process: a. Quarry and/or Mine Activities: Use the PI-03 form to describe all storage and handling activities. b. Raw Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. c. Non-Metallic Mineral Processing (crushing and sizing of raw materials): Use the PI-18 form to describe the mineral processing activities. d. Ground Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. e. Pre-heater / Pre-calciner: To adequately describe the pre-heater or pre-calciner, complete the PI-02A to summarize the combustion units, Complete the PI-02B to describe each pre-heater or pre-calciner, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. f. Fuel type for Pre-heater / Pre-calciner: Complete the PI-02F form is a fuel other than natural gas is used. g. Kiln: To adequately describe the kiln, complete the PI-02A to summarize the combustion units, Complete the PI02E to describe each kiln, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. h. Fuel Type for Kiln: Complete the PI-02F form is a fuel other than natural gas is used. i. j. Clinker Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. Non-Metallic Mineral Processing (crushing and sizing of clinker): Use the PI-18 form to describe the mineral processing activities. 2. Form: PI-03: Storage and Handling of Bulk Material PI-02A: Combustion Unit Summary PI-02B: Combustion ­ Boilers, Process Heaters & Furnaces PI-02E: Combustion ­ Kilns PI-02F: Combustion ­ Fuel Use PI-02G: Combustion ­ Emission Factors PI-02H: Combustion ­ Federal Rule Applicability American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 2 of 5 PI-15 Instructions 10/2006 PI-18: Mineral Processing Part B: Portland Cement Manufacturing Summary Part B summarizes the Portland cement manufacturing process. 3. Maximum Amount of Raw Material Processed: Quantify the maximum amount of raw material processed in tons per hour (ton/hr) and tons per year (tpy). 4. Raw Material: Identify each raw material used and include the percentage by weight (%) used compared to the total amount of raw materials processed. If there is another raw material applicable beyond the listed items, specify the raw material under the "other" option. 5. Maximum Amount of Portland Cement Produced: Provide the maximum amount of Portland cement produced in tons per year (tpy). Part C: Federal Rule Applicability Part C identifies any federal rules that apply to the process. 6. Is a New Source Performance Standard (NSPS) applicable to this source? Specify whether a New Source Performance Standard (NSPS) is applicable to the process unit(s). If a New Source Performance Standard (NSPS) applies, list the rule citation and title in the space provided and submit a FED-01 form to identify the applicable portions of the rule. 7. Unit IDs: Provide the identification numbers for the process units that are subject to an NSPS. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 8. Is a National Emission Standard for Hazardous Air Pollutants (NESHAP) applicable to this source? Specify whether a National Emission Standard for Hazardous Air Pollutants (NESHAP) is applicable to the process unit(s). If a National Emission Standard for Hazardous Air Pollutants (NESHAP) applies, list the rule citation and title in the space provided and submit a FED-01 form to identify the applicable portions of the rule. The United States Environmental Protection Agency (U.S. EPA) provides lists of NESHAP on the Rules and Implementation section of the Air Toxics Website. 9. Unit IDs: Provide the identification numbers for the process units that are subject to a NESHAP. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 10. Non-Applicability Determination: Provide an explanation of non-applicability if the process unit would appear to be subject to a rule (based on the rule title of affected source category), but the rule will not apply to the process. For example, if the process unit is part of the source category subject to a rule, but the process unit in question is not subject to the rule, state the reason why the unit is not subject. Part D: Cement Kiln Dust Operations Part D identifies the components associated with the Cement Kiln Dust (CKD) operations. 11. Type of Equipment: Specify the type of equipment used for cement kiln dust operations. 12. Unit ID: For each equipment type listed, provide the identification number(s) for the process unit(s). Please list each emission unit on a separate row, unless they are identical. Identical uni